This section describes potential problems, possible causes, actions/ repairs to complete for various furnace issues. If the problem is not described below, or suggested corrective actions are not successful, please contact support.
Note: many troubleshooting procedures require manual control via the status panel on the touchscreen interface. See Software Interface for details.
| Problem | Possible Cause | Action/Repair |
| Furnace will not turn on. | Furnace is unplugged. | Verify that the power cord is plugged into the wall outlet. |
| Furnace breaker flipped. | Contact support@rapidia.com. Error code: “Input Circuit Breaker blown” will show up in log files. | |
| Failure of building power. | If there was a general power failure during a sintering cycle, the furnace will be in a safe state to cool down. Once power is restored, the furnace will turn back on. Wait until it has cooled to 150°C before doing anything further. | |
| Furnace tripped wall breaker. | If only the wall circuit breaker tripped and the furnace was recently installed, verify that the furnace is on a dedicated circuit, and verify that the breaker is rated to the correct current. If this does not identify the problem, contact support. | |
| Furnace combined with other loads tripped supply breaker upstream of dedicated circuit breaker. | If the circuit protection specifically for the furnace did not trip, verify that the breakers upstream are properly rated and also did not trip – breakers already close to their capacity, used for example for electric heating, may be overloaded if the load of the furnace is added. | |
| Screen is black. | Screen is unplugged. | Verify that the connecting cables have been properly installed, as described in Touchscreen Connection. |
| Shelves are damaged. | Physical impact or exceeded thermal cycling lifetime. | If the ceramic or graphite shelves are chipped, they are still usable. If they are cracked, do not use. Contact support to request a replacement. |
| Furnace moves when attempting to close the door. | Casters are not locked. | Refer to Locking Casters for instructions on how to lock casters. |
| Furnace door will not close. | Internal baffle plug may be misaligned. | Check alignment of the baffle plug with the retort. Ensure that it is not bumping into the face ring that holds the O-ring. |
| Locking fingers may be bent or misaligned, preventing them from locking. | Verify the locking fittings are not hitting anything when closing the door. Ensure the handle is rotated counter-clockwise before attempting to push the door in and lock. If this is insufficient, contact support@rapidia.com. | |
| O-ring protrudes out of groove. | Check that the O-ring sits in the groove properly. | |
| Shelves may be improperly inserted. | Check that shelves are in place (touching diffuser plate at the rear of retort). See Loading The Trays Into The Retort. | |
| Gas inlet/outlet tubes inside the furnace may be protruding too much. | Check that gas fittings at the bottom of the retort are not protruding too far upwards. | |
| Gas inlet tube may be rotated out of alignment. | Check that the gas inlet tube is running straight along the bottom of the retort. The graphite block it inserts into should be at the 6 o’clock position in the rear of the retort. | |
| Error: “Furnace Restarted After Fatal Error - {Reason}” |
Resolve the issue before continuing. | |
| Error: “Serial Number Not Configured” |
Serial Number not configured | Contact support@rapidia.com for instructions on how to use the “Settings/More” dialog to enter the serial number from the back of the furnace into the serial number parameter. |
| Error: “Furnace restarted after bad shutdown - Check backup battery.” |
Backup battery disconnected | Re-connect backup battery |
| Backup battery discharged or other issue | Contact support@rapidia.com | |
| Error: “Temperature Sensor Not Connected” |
Thermocouple wires are not properly connected | Verify that thermocouple wires are connected at the thermocouple junction block. See Replacing the Thermocouples. |
| Problem | Possible Cause | Action/Repair |
| Error: “Low Sintering Gas Pressure - Make sure that total sintering gas pressure is at least {GasPressure} psi and that the valves to connected tanks are open. Measured pressure in tank1 is {Tank1} psi, tank2 is {Tank2} psi. After fixing, hit the OK button.” |
Argon tank is not connected. | Check that a gas tank is connected to the regulator (Section Replacing Gas Tanks). |
| Argon tank valve not open. | Verify that the valve on top of the argon tank is open (correct direction is indicated by arrows on handle). | |
| Argon tank is empty. | Check that gas tank pressure is non-zero on both high pressure and low-pressure regulators. If the high pressure gauge is at zero, replace the tank. If the low pressure gauge is at zero, carefully adjust it upwards to 3psi. | |
| Pressure transducer is not plugged in. | If there is sufficient gas pressure, verify that the pressure transducer is plugged in to the rear of the furnace. See Back Panel. | |
| Pressure transducer is not functioning | If the pressure transducer is plugged in and there is sufficient gas, contact support for assistance. | |
| Error: “Front Heat Power - Front Heat Power missing or breaker blown” |
Front heat breaker has flipped | Contact support@rapidia.com |
| Power detection system is malfunctioning. | Contact support@rapidia.com | |
| Error: “Error reading from absolute pressure sensor: Status = {pressureSensorStatus}” |
Communication with vacuum pressure controller is not functioning | Contact support@rapidia.com |
| Error: “Failed to achieve vacuum – Check that door is sealed” |
Retort door is not properly closed | Check that retort door is closed (handle turned clockwise to seal) |
| Retort O-ring is not properly seated | Confirm that the O-ring is in place. Replace if necessary (see Section Retort Overview). | |
| A vacuum connection is open | Check that no vacuum piping has been left undone after maintenance. Verify that the steps in Section Reassembly have been completed if maintenance has been done. | |
| Vacuum pump is not turning on. | Verify that the vacuum pump is turning on (listen for sound in lower cabinet) - if not, check its switch is turned on. The switch of the pump is located on the back of the pump. | |
| Pressure sensor is damaged. | Pressure sensor may be damaged or have residue on the diaphragm. With furnace door open, verify that Pressure reading in Status Panel is around atmospheric (760-780 Torr at sea level or lower with increasing altitude). If it gives abnormal readings, contact support. | |
| Error: “Throttle Valve blocked or disconnected” |
Throttle valve does not allow sufficient gas to pass through during test | Contact support@rapidia.com |
| Error: “Outlet tube obstructed or leak detected in Retort: Check retort outlet tube in furnace and clean if obstructed.” |
Retort outlet tube is clogged. | Inspect and clean as described in Section Cleaning the Retort Gas Outlet Tube. |
| Parts that are still wet are releasing water vapor | Remove parts from furnace and try the self test again. If the self-test succeeds with the parts removed, cancel the cycle and allow the parts to dry before running them. | |
| There is a leak in the vacuum system. | Contact support@rapidia.com | |
| Error: “Low Sintering Gas flow” |
Pressure at regulator is set incorrectly | Refer to Section Setting and Adjusting the Gas Flow. |
| Flowmeter needle valve is improperly adjusted. | Refer to Section Setting and Adjusting the Gas Flow. | |
| Solenoid valve is stuck closed. | In the Status Panel, press the Argon button and listen for a click from the solenoid. If it makes no sound, the solenoid may require cleaning.* Contact support for details | |
| Error: “High Sintering Gas flow: Expected < {MaximumRetortFlowTorr} Torr/Minute, Measured/Minute= {Flow} Torr/Minute” |
Pressure at regulator is set incorrectly | Refer to Section Setting and Adjusting the Gas Flow. |
| Flowmeter needle valve is improperly adjusted. | Refer to Section Setting and Adjusting the Gas Flow. | |
| Error: “Sintering Gas Feed Error - Open tank valve for sintering gas and continue” |
The valve on top of the gas tank is closed | Open the valve on the top of the tank and try again. |
| Error: “Persistent limit controller over temperature fault. Sensed limit controller temperature is {Temperature} °C” |
Furnace temperature has exceeded maximum setting. Error in limit controller |
Contact support@rapidia.com |
| Error: “Cooling fan stalled” |
One of the four cooling fans at the front of the furnace is blocked | Check cooling fans for obstructions after unplugging machine. See Vacuum Exhaust System Overview. |
| Error: “At least one of the cooling fans is missing” |
At least one of the four cooling fans is not drawing current. | Check that all four fans are plugged in. See Vacuum Exhaust System Overview. |
| Error: “The cooling fans are disconnected.” |
All of the cooling fans are disconnected. | Check that all four fans are plugged in. See Vacuum Exhaust System Overview. |
| Problem | Possible Cause | Action/Repair |
| Error: “Under Temperature Error: Target = {targetTemperature} Measured = {currentTemperature}” |
Broken heating element. | Verify that a heating element is not broken, which would prevent the furnace from heating. Contact support for details. |
| High commanded heating rate. | Contact support@rapidia.com |
| Problem | Possible Cause | Action/Repair |
| Parts are dull or discolored. | Gas flow stopped due to gas running out | Check the instructions for “High Sintering Gas flow” error. |
| Internal gas tube cracked | Check the gas tube in the furnace to ensure it is not cracked. See Retort Overview. Contact support for help if a replacement is needed. | |
| There is a leak at the front O-ring. | See Section Replacing the Face O-ring for inspection and cleaning procedures. | |
| There is a leak where the regulator attaches to the gas tank | Double check that the regulator is sealed tightly to the gas tank. See Section Replacing Gas Tanks. | |
| There is a leak elsewhere in the vacuum system. | If any fittings have recently been disconnected, they may not have been properly re-tightened. VCO fittings should be tightened hard, allowing the metal to bottom out and ensuring good compression of the o-ring. Also tighten fittings at either end of the stainless steel tubing connecting the pressure regulator to the furnace (Section Replacing Gas Tanks). | |
| Parts are melted | Thermocouple drifted, reads too low | Contact support@rapidia.com |
| Incorrect cycle selected | Check to ensure that the cycle matched the material. | |
| Parts are not fully sintered (insufficient densification) | Thermocouple drifted, reads too high | Contact support@rapidia.com |
| Incorrect cycle selected | Check to ensure that the cycle matched the material. | |
| Impossible to open the furnace. | The door interlock cannot function due to the door handle contacting it. | Try rotating the handle clockwise slightly (i.e., in the “Lock Direction”). Press the “Door Unlock” button, and then try again to open the door by rotating the handle counterclockwise. |
| There is insufficient sintering gas to bleed the furnace to atmospheric pressure. | Contact support@rapidia.com | |
| Higher or lower than typical Argon usage (based on decrease in regulator pressure during a sintering cycle). | Flowmeter may be adjusted incorrectly. | Refer to Section Setting and Adjusting the Gas Flow. |
| Error detected during door unlock – “Obstructed Outlet Tube: Measured drop in pressure of NNN Torr with door open. Clear obstruction and perform door unlock to check that issue is resolved” | Retort outlet tube is clogged. | Inspect and clean as described in Section Cleaning the Retort Gas Outlet Tube. |
| Ceramic setters are bent | Use of ceramic setters without graphite shelves | Refer to Section Tray Selection and Assembly |
| Parts have fallen over | Ceramic setters are bent | See above |